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Operation Results of IHI Flue Gas Desulfurization System

– Unit No.1 and 2 (600 MW × 2) of Wangqu Thermal
Power Station for Shanxi Lujin Electric Power –

TSUMITA Yoshimitsu : Manager, Basic Design Department, Power Plant Division, Energy Plants
Operations
TAKAMI Akira : Manager, Power Plant Division, Energy Plants Operations
TODA Koji : Manager, Basic Design Department, Power Plant Division, Energy Plants
Operations
FUJINO Yoshihisa : Basic Design Department, Power Plant Division, Energy Plants Operations
FUJII Keita : Basic Design Department, Power Plant Division, Energy Plants Operations

An IHI f lue gas desulfurization ( FGD ) system was completed for 600 MW×2 coal-fired thermal
power plant at Wangqu Lujin, China, in August 2006, which was one of largest-capacity plants in Shanxi
province. This was constructed as the first FGD system in the province and is now operating smoothly and
demonstrating superior SO2 removal efficiency with high operational reliability. The conventional design with
proven technologies was applied to cope with the local stringent environmental regulations. IHI supplied the
basic design for a local engineering company, which was in charge of the details and civil engineering design
for the FGD system.

In this paper, we introduce the wet type f lue gas

1. Introduction desulfurization system of Phase 1 Units Nos. 1 and 2
In China, the air pollution legislation was revised of Wangqu Thermal Power Station for Shanxi Lujin
in 2004 and air pollution control was strengthened Electric Power, the delivery of which was completed as
against coal-fired power plants. For this reason, it is the first step of the basic design package supply.
mandatory to install flue gas desulfurization systems
for construction of new thermal power plants, and it 2. Outline of phase 1 units Nos. 1 and 2 of
is estimated that there will be a demand for f lue gas Wangqu thermal power station
desulfurization systems of 20 million kW per year in The Phase 1 Units Nos. 1 and 2 of Wangqu Thermal
the future. In the environmental equipment market in Power Station started their commercial operation in
China, however, there are many competing companies, August 2006 as a new and powerful coal-fired power
and it is considered that it will be increasingly difficult plant of the largest scale in Shanxi Province. Its outline
for each company to obtain orders for EPC (work is as follows.
including design, procurement, and installation in the Figure 1 shows the overall view of the wet type flue
supply range). For this reason, our company established gas desulfurization system of Phase 1 Wangqu thermal
a policy to specialize in engineering mainly consisting power station.
of sof t ware by const r ucting a new model called Generator outpu 600 MW × 2
basic design package supply aiming at developing Boiler
environmental businesses in China. Type Supercritical pressure boiler
U n d e r s u c h a p ol i c y, t h e w e t t y p e f l u e g a s Fuel used Coal
desulfurization system of Phase 1 Units Nos. 1 and 2 Evaporation 1 944 t/h/unit (at maximum
of Wangqu Thermal Power Station for Shanxi Lujin continuous load)
Electric Power was constructed making the best use of Steam pressure 24.2 MPa
our company’s many achievements and experiences in Steam temperature 566˚C /566˚C (main steam /
the field of flue gas desulfurization systems for coal- reheat steam)
fired power plants and delivered as the latest system Combustion system Single fuel firing by coal
integrating our accumulated technologies, and all the Environmental preservation equipment
construction processes were accomplished and the Electrostatic precipitator (EP)
delivery to the customer completed in December 2006. Low temperature electrostatic

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precipitator
Flue gas desulfurization system (FGD) 3. Wet type flue gas desulfurization system
Wet type limestone-gypsum 3.1 Specifications
process Main specifications are as follows. Figure 2 shows the
Waste water treatment system (WWTS) general equipment arrangement.
No. 1 coag ulation and Type Wet type limestone-gypsum
sedimentation/sand filter process (simultaneous
desulfurization and
oxidation)
Capacity
Flue gas flow rate (wet) at inlet
1 938 100 m3N /h (per boiler)
Flue gas temperature at inlet
121˚C
SO2 concentration
At FGD inlet 1 246 mg/m3N
(O2 concent rat ion : 6%
conversion value)
At FGD outlet 33 mg/m3N or less
(O2 concent ration : 6%
conversion value)
Gypsum moisture content
Fig. 1 View of FGD of Wangqu Thermal Power Station
10 wt% or less

@7 @8 @6

Street

t
u y

w q

r e
!1 !0
Street Street

!4
!7 @4
!6 @3 i @5
!9 !8
!5 @0 @1
!3 o
@2

!2

(Note) q : No. 1 unit boost up fan (BUF)
w : No. 2 unit boost up fan (BUF)
e : No. 1 unit absorber
r : No. 2 unit absorber
t : Circulating pump room
y : No. 1 unit absorber slurry recycle pump
u : No. 2 unit absorber slurry recycle pump
i : No. 1 unit oxidation air fan
o : No. 2 unit oxidation air fan
!0 : No. 1 unit absorption system drain pit
!1 : No. 2 unit absorption system drain pit
!2 : Emergency blow tank
!3 : Eliminator washing water tank
!4 : Limestone slurry pit
!5 : Limestone silo
!6 : Filtrate tank
!7 : Small pump room
!8 : Vacuum belt filter room
!9 : Primary hydrocyclone overflow tank
@0 : Washing water tank
@1 : No. 1 unit vacuum pump
@2 : No. 2 unit vacuum pump
@3 : Secondary hydrocyclone overflow tank
@4 : Gypsum system drain pit
@5 : Desulfurization control room
@6 : No. 1 unit bypass damper
@7 : No. 2 unit bypass damper
@8 : Stack

Fig. 2 General arrangement

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Gypsum purity 97.2 wt% or more absorbent, and t waste water treatment system to treat
Main equipment (quantity for 2 boilers) the waste water from the gypsum dewatering system.
Absorber Figure 3 shows the processes of this wet type flue gas
Type Spray type desulfurization system.
Quantity 2 units 3.2.1 Boiler air and gas system
Outside dimensions 17.0 m (diameter) × 30.0 m Unt reated gas discharged f rom the boiler passes
(height) through the gas air heater, electrostatic precipitator, and
Boost up fan (BUF) induced draft fan (IDF), and is increased in pressure
Type Variable pitch axial flow fan by the boost up fan (BUF) and sent to the absorber for
Capacity 30 360 m3/min × 3.083 kPa desulfurizing and dust removal. Then the mist carried
Quantity 4 units in the treated gas is removed by the mist eliminator
Motor output 2 500 kW installed in the absorber and the gas is discharged into
Absorber slurry recycle pump the atmosphere through the stack.
Type Centrifugal type (impeller : 3.2.2 Absorption system
anti-corrosion alloy, casing : SO2 in the untreated gas introduced into the absorber
rubber lining) is absorbed and removed by spray solution containing
Capacity 113.0 m3/min limestone sprayed into the absorber. The absorbed SO2
Quantity is forcefully oxidized by oxygen in the air blown into
1st bank 4 units the absorption slurry at the bottom of the absorber and
2nd bank 4 units immediately becomes gypsum. The main reactions in
3rd bank 4 units this process are as follows.
Motor output SO2 + CaCO3 + 1/2O2 + 2H 2O
1st bank 630 kW → CaSO4 · 2H 2O + CO2 ↑
2nd bank 710 kW The gypsum slurry produced through the reactions
3rd bank 710 kW in the absorber is intermittently sent to the gypsum
Vacuum belt filter (common to units 1 and 2) dewatering system from the absorber. Figure 4 shows
Type Vacuum belt filter the outline of the absorber of this wet type f lue gas
Capacity 42 m 2 (filter area) desulfurization system.
Quantity 2 units (1 unit in operation + 3.2.3 Gypsum dewatering system
1 unit as spare) The bleed slur r y from the absorber is sent to the
Limestone silo (common to units 1 and 2) gypsum hydrocyclone and separated into underf low
Capacity 1 300 m3 and overf low by centrifugal force. The underf low
Quantity 1 unit (solids relatively large in particle size containing much
Waste water treatment system (common to units 1 gypsum) of the primary hydrocyclone is supplied to the
and 2) gypsum dewatering system, dewatered, and recovered
Type No. 1 coag u lat ion a nd as gypsum with moisture content of not more than 10%.
sedimentation + sand filter On the other hand, the overf low (solids relatively
Capacity Maximum 240 t/d small in particle size mainly containing limestone and
Quantity 1 set soot/dust) of the primary hydrocyclone is stored in the
Absorbent and byproduct (design value for 1 boiler) tank and then sent to the secondary hydrocyclone by the
Limestone powder consumption pump and separated again into underflow and overflow
11.0 t/h by centrifugal force.
Gypsum 22.0 t/h The underf low (solids relatively large in particle
Utilities (design value for 1 boiler) size containing much limestone) of the secondary
Industrial water 70.5 t/h hydrocyclone is retur ned to the absorber and the
Waste water 7.5 t/h unreacted limestone in the liquid is effectively reused.
Maximum power consumption On the other hand, the overf low (solids relatively
10 200 kW (for 2 boilers) small in particle size containing much soot/dust) of
3.2 Process the secondary hydrocyclone is sent to the waste water
T h is wet t y p e f lue ga s d e s u l f u r i z at ion s ys t e m treatment system and treated on SS (suspended solid)
consists of 5 systems : q boiler air and gas system and heavy metal.
to send exhaust gas from the boiler to the absorber F ig u re 5 shows t he processes of t he g y psu m
and introduce treated gas to the stack, w absorption d e w a t e r i n g s y s t e m of t h i s w e t t y p e f l u e g a s
system to collect SO2 from the exhaust gas and produce desulfurization system and Fig. 6 the classifying
gypsum, e gypsum dewatering system to recover principle of the two-stage hydrocyclone.
the produced gypsum as a byproduct, r limestone 3.2.4 Limestone preparation system
preparation system to prepare the limestone slurry as a The limestone (particle size 250 mesh : about 50μm),

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 No. 1 unit
Desulfurization
outlet damper
Limestone silo
Mist
eliminator

Desulfuri-
zation inlet Boost up fan Limestone feeder
Boiler Electrostatic Induced damper
precipitator draft fan Absorber M
slurry recycle
pump
Bypass Boost up fan M Secondary
Absorber
damper Oxida- Absorber hydrocyclone
tion bleed pump Limestone slurry
air fan pit
Absorber agitator

Desulfurization
outlet damper
M M

Mist Waste water

Stack eliminator Primary Primary
Bypass hydrocyclone hydrocyclone treatment system
damper Primary hydrocyclone Secondary hydrocyclone
Boost up fan overflow tank overflow tank
Desulfurization
inlet damper
Gypsum Gypsum dewatering unit
Gypsum Gypsum
No. 2 unit Absorber dewatering Atmosphere Atmosphere
slurry recycle pump unit
Boost up fan M Vacuum Vacuum
Oxida- Absorber bleed pump pump
Absorber pump Separa- Separa-
tion tor tor
air fan
Absorber agitator Vacuum Vacuum
Mist eliminator tank tank
washing water tank
Boiler Electrostatic Induced Vacuum Vacuum
precipitator draft fan tank pump tank pump
Makeup
water

Filtrate tank Washing water

tank

Fig. 3 Process flow of FGD

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!2 u y absorbent, is transported into the plant by jet pack

vehicle, pumped into the limestone powder silo and
Gas stored, and then the necessary quantity is charged into
the limestone slurry pit by a rotary feeder and prepared
w
as limestone slurry.
t 3.2.5 Waste water treatment system
t
The overflow of the secondary hydrocyclone is sent to
the tank and then to the waste water treatment system,
and SS in the waste water is roughly removed in the
initial settling tank. The treated supernatant liquid
e
!2 is sent to the sand filter in which final SS removal is
30 000

Flake lining r made, thus creating properties dischargeable outside the

f17 000
!1 !0 !2
(Note) q : Gas inlet nozzle
w : Gas outlet nozzle
e : Recycle spray piping
r : Recycle spray nozzle
t : Mist eliminator
y : Mist eliminator washing
water piping
Fig. 4 Schematic drawing of absorber (unit : mm)
Gas system.
4. Technologies adopted and order receiving
q
form
o
4.1 Technologies adopted
T he process select ion of t h is wet t y pe f lue ga s
desulfurization system, absorber size and performance
and equipment specifications were decided based on our
company’s design and past technological achievements
i of desulfurization system plants. The basic design
was made in due consideration of fully meeting the
u : Mist eliminator washing customer’s requirements for a system to ensure stable
spray nozzle
i : Oxidation air piping
operation and easy maintenance while maintaining
o : Absorber agitator suff icient desulfurization eff iciency to satisfy the
!0 : Absorber internal strainer environmental control values. It was, however, decided
!1 : Recycle liquid outlet nozzle not to install the GGH (gas-gas heater) nor mally
!2 : Manhole
installed for domestic wet type flue gas desulfurization
systems to prevent diffusion of f lue gas and white
smoke, in accordance with the customer’s intention. For
this reason, we made design considerations on material
selection at the inlet/outlet of the absorber, method of

Primary
Absorber hydrocyclone

Primary hydrocyclone
overflow tank

Vacuum Atmosphere
belt
filter
Gypsum
Separator Secondary
hydrocyclone

Vacuum Absorber
pump M

Vacuum Vacuum Waste water

receiver receiver treatment system

Absorber
Secondary hydrocyclone
M overflow tank
Limestone
slurry pit Washing water tank
Makeup water

Filtrate tank

Fig. 5 Process flow of gypsum dewatering system

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Overflow (small particle size = limestone + fly ash)
Absorber
bleed slurry Primary
hydrocyclone
Underflow (large particle size = gypsum)
Fig. 6 Principle of two-stage hydrocyclone classifier
treating condensed water produced in the f lue, and
maintenance when the plant is stopped.
4.2 Order receiving form
This work was the first for which our company received
an order for the basic design package supply.
IHI took charge of the basic design of the wet type
f lue gas desulfurization system mainly consisting
of process selection, decision on absorber size and
performance, decision on equipment specifications
and basic arrangement of apparatuses, and the project
management. An engineering company in China was
in charge of the purchase of apparatuses and detailed
designing of f lue, piping, and supports in China and
another engineering company in China was in charge
of the planning of foundation works of the building and
equipment. The work ranges of the companies were
decided based on the drawings issued, and efforts were
made to strictly control them, including costs.
5. Operation results
For this wet type f lue gas desulfurization system, we
started the site installation of both No. 1 and No. 2
units in April 2005, conducted trial operation of each
unit after receiving power in April and June 2006, and
confirmed that the performance and reliability of each
unit were sufficiently satisfied.
Subsequently, we conducted the general water
oper at ion i nclud i ng sequence t est a nd i nt erlock
test and confirmed there was no problem with the
safety or controllability of any of the equipment, and
completed the gas supply to the flue gas desulfurization
system for No. 1 unit and No. 2 unit in August and
November 2006, respectively. We then conducted
168 hour continuous operation (operation required
in the specification) with actual gas. We completed
the performance test of No. 1 unit and No. 2 unit in
September and December 2006, respectively, and
confirmed that this equipment satisfied the performance
and function requirements as planned.
5.1 Trial operation of each unit and general water
operation
In the testing of each unit, we checked on the following
items and made adjustments and confirmed there was no
problem.
(1) Performance of unit
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Overflow (small particle size = fly ash)
Waste water
treatment system
Secondary
hydrocyclone
Primary hydrocyclone
overflow tank
vacuum belt filter Underflow (large particle size = limestone) absorber
(2) Conditions during operation (vibration of unit,
noise, temperature of lubricating oil, etc.)
(3) Controllability
In the general water operation, we mainly checked
on the following items and made adjustments and
confirmed that there was no problem in starting the trial
operation with actual gas.
(1) Starting and stopping through master sequence
(2) Alarm/interlock tests
(3) Draft balance test
(4) Absorber spray test
(5) Mist eliminator automatic washing and spray test
(6) Material balance and water balance
5.2 Adjustment of draft control system
As to the controllability of the draft of the boiler
air and gas system when switching is done from the
IDF rotor blade opening follow-up control when the
by pass damper is “OPEN” to the by pass damper/
draft differential pressure control when the damper
is “CLOSE,” we made the following adjustments and
confirmed good controllability through the draft balance
test.
(1) Adjustment of Closing timing and speed of the
bypass damper blade
(2) Adjustment of timing of starting mode changing
from IDF rotor blade opening follow-up control to
bypass damper/draft differential pressure control
5.3 Performance test
To confirm that this wet type flue gas desulfurization
system satisf ied the perfor mance as plan ned, we
conducted performance tests at boiler loads of 100% and
75%. Table 1 shows the results of the performance tests.
The results were good, showing that the desulfurization
efficiency sufficiently satisfied guaranteed values in the
entire boiler load range.
The byproduct gypsum satisfied the guaranteed values
of purity, moisture, and limestone stoichiometric ratio
and is effectively reused as a cement additive. In the
90 day continuous operation of the equipment, 100%
operation was achieved at the operation rate of each
unit. We also confirmed that it had high operational
reliabilit y, sat isf yi ng g u a ra ntee items related to
reliability required of this work.
5.4 Load following test
Cor responding to load changes of the boiler, we
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Table 1 Results of performance tests

Performance test result

Guaranteed
Guarantee item Unit Boiler load
value
Boiler classification 100% 75%
mg/m3 N
No. 1 unit 15.3 13.8
Stack inlet SO2 concentration ≤71.5
(dry, 6% O2) No. 2 unit 19.8 11.3
No. 1 unit 99.0 99.0
Desulfurization efficiency % ≥97.2
No. 2 unit 98.8 99.3

Limestone stoichiometric ratio No. 1 unit 1.03 —

— ≤1.03
(in gypsum) No. 2 unit 1.00 —
No. 1 unit 6 915 —
Power consumption kW · h ≤10 200
No. 2 unit 5 156 —

Absorber outlet mist No. 1 unit 48.8 36.1

concentration
mg/m3N ≤75
No. 2 unit 42.6 38.8
No. 1 unit 46.4 44.0
Stack inlet gas temperature ˚C ≥45
No. 2 unit 46.0 43.0
No. 1 unit 92.8 —
Gypsum purity % ≥90
No. 2 unit 91.2 —
No. 1 unit 10.0 —
Gypsum moisture % ≤10
No. 2 unit 10.0 —

Plant reliability No. 1 unit 100 —

% ≥98
(90 day continuous operation rate) No. 2 unit 100 —

conducted load following tests at the loads of 100, 75,
60 and 40% and confirmed good characteristics of load
following of the desulfurization performance, BUF
volume control, absorber bleed control, and limestone
supply control in both load increasing and decreasing.
5.5 Tests changing absorber conditions
C h a ng i ng op e r at ion c ond it ion s of t he abs or b e r
(operation pH, liquid level of absorber, etc.), we
determined the effects on the desulfurization/oxidation
performance and waste water properties and obtained
various data usef ul for optimal f ut ure equipment
operation, including selection of proper operation
conditions of the absorber in accordance with the FGD
inlet gas conditions.
6. Conclusion
This project has drawn much attention within China
b e cau se it conce r ne d a la rge wet t y p e f lue ga s
desulfurization system, the f irst of its kind in the
Shanghai area, but as a result of the trial operation and
performance tests, we confirmed high desulfurization
per for mance and also good load following
characteristics and high operational reliability. We
received good customer satisfaction not only in the
equipment performance and operation but also for our
support in the progress course of the project.
In the future, we intend to do our best in promoting our
desulfurization technologies in the FGD market of China
by taking advantage of our experience obtained through
this project.
– Acknowledgements –
In this project, we received extensive cooperation from
the government of China, many enterprises, and people
concerned from the design stage. We hereby express our
heartfelt thanks to them.

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